Custom Formable Footbed and Shoe Insert

ABSTRACT

A customizeable footbed, a self-customizing footwear having a customizable footbed, and a method for customizing a footbed to conform to contours of a foot is provided. The customizable footbed may include a plurality of packets, each packet comprising an exterior membrane defining a chamber therein, and an interior filling within the chamber. The interior filling may be selected from a group consisting of two or more components of a curable material that chemically react upon mixing of the components to irreversibly form a solid or semi-solid resin or a gel. The plurality of packets may be configured to burst upon application of a pressure such that the interior fillings of the packets flow into and mix within the intermediate space.

PRIORITY CLAIM

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 62/295,863 filed Feb. 16, 2016, the entire contents of which ishereby incorporated by reference herein.

BACKGROUND

Shoe inserts have long been used to provide better fit, feel and supportfor the foot within a shoe. Such inserts range from simple linings, tocontoured paddings, to support orthotics. They also range frominexpensive standard insoles, to very expensive custom-fit inserts.Inexpensive insole options, which often fail to provide sufficient fitand comfort, are currently produced by one of the following methods:“boil and wear” type solutions, ski-shop spray or heat form solutions.More custom-fit or personalized shoe inserts tend to be very expensive,and the fitting process sometimes involves a trip to a physician'soffice or to a location with specialized fitting equipment where a scanor mold of the foot can be made. The customer will often have to waitdays or weeks for delivery of the final insert.

The present invention relates to an improved custom-fit, personalizedfootbed or insole that is inexpensive and easy to use.

SUMMARY OF THE INVENTION

In accordance with the foregoing objectives and others, one embodimentof the present invention provides a customizable footbed. Thecustomizable footbed comprises a top layer which, when the footbed is inan operating configuration faces a bottom of a foot. The customizablefootbed also comprises a bottom layer opposite the top layer which, whenthe footbed is the operating configuration is positioned away from thebottom of the foot. The top and bottom layers defining an intermediatespace therebetween. For example, the bottom layer may comprise anelastomeric polymer. The customizable footbed further comprises aplurality of packets arranged within the intermediate space. Each packetmay comprise an exterior membrane defining a chamber therein, and aninterior filling within the chamber. The exterior membrane may comprisea thermoplastic polymer, in particular a low-density polyethlyenepolymer. The exterior membrane may also have an average thickness fromabout 5 mm to about 10 mm. The interior filling may be selected from agroup consisting of two or more components of a curable material thatchemically react upon mixing of the components to irreversibly form asolid or semi-solid resin or a gel. The curable material may be atwo-component or multi-component resin that spontaneously reacts uponmixing of the components. For example, the curable material may beselected from a group consisting of polyurethane resins, siliconeresins, epoxy resins, and melamin resins. In another example, thecurable material may be a quick-curing material that solidifies into adesired shape within 30 mins upon mixing of the components. Theplurality of packets may be configured to burst upon application of apressure corresponding to that of the foot being rocked back and forthon the top layer such that the interior fillings of the packets flowinto and mix within the intermediate space. For example, the pluralityof packets may be configured to burst upon application of a pressurefrom about 0.1 N/cm² to 1 kN/cm². In some examples, each of theplurality of packets may have a three-dimensional shape. In particular,the three-dimensional shape may be selected from a group consisting ofhemis-spherical, cubic, hexagonal prism, pentagonal prism, rectangularprism, square prism, cone, and tetragonal pyramid shapes. Moreparticularly, the each of the plurality of packets may have a squareprism shape, in particular, a ratio of a width and a height of thesquare prism is from about 1:2 to about 2:1, specifically 1:1. In oneexample, the plurality of packets may be uniformly sized and shaped, andarranged in a two-dimensional array. Furthermore, the packets may bespaced apart by a distance from about 0.05″ to about 0.1″. In anotherexample, the plurality of packets may be arranged to form at least afirst two-dimensional array across a first section of the footbedcorresponding to a first portion of the foot, and a second array forminga second section of the footbed corresponding to a second portion of thefoot. Furthermore, the plurality of packets may be formed from a singlyshaped polymeric film bonded to a flat polymeric film.

In one aspect, a self-customizing footwear is provided. Theself-customizing footware may comprise an upper, an insole, and anoutsole. The insole comprises a top layer which, when the insole is inan operating configuration is faces a bottom of a foot. The insole alsocomprises a bottom layer opposite the top layer which, when the insoleis the operating configuration is positioned away from the bottom of thefoot. The top and bottom layers defining an intermediate spacetherebetween. The insole further comprises a plurality of packetsarranged within the intermediate space, each packet comprising anexterior membrane defining a chamber therein, and an interior fillingwithin the chamber. The interior filling may be selected from a groupconsisting of two or more components of a curable material thatchemically react upon mixing of the components to irreversibly form asolid or semi-solid resin or a gel. The plurality of packets may beconfigured to burst upon application of a pressure corresponding to thatof the foot being rocked back and forth while wearing the footware suchthat the interior fillings of the packets flow into and mix within theintermediate space.

In another aspect, a method for customizing a footbed to coform tocontours of a foot is provided. The method may comprise a first step ofapplying a pressure to burst a plurality of packets. Each packetcomprising an exterior membrane defining a chamber therein, and aninterior filling within the chamber. The interior filling may beselected from a group consisting of two or more components of a curablematerial. The method may also comprise a step of mixing the componentsof the curable material to initiate a chemical reaction such that thecomponents irreversibly react to form a solid or semi-solid resin or agel. The method may further comprise a step for holding the foot againstthe footbed for a period of less than 30 mins such that the curablematerial reacts to form a shape comforming to the courtours of the foot.

In a futher aspect, an alternative embodiment for a customizeablefootbed is provided. The customizable footbed comprises a top layer anda bottom layer. The customizable footbed further comprises a pluralityof blister packets arranged between the top and bottom layers. Eachpacket comprises an exterior membrane defining a chamber therein, and aninterior filling within the chamber. The interior filling may beselected from a group consisting of two or more components of a curablematerial that chemically react upon mixing of the components toirreversibly form a solid or semi-solid resin or a gel. The plurality ofblister packets may be configured to rupture upon application of apressure corresponding to that of the foot being rocked back and forthon the top layer such that the interior fillings of the packetsintermix.

These and other aspects of the invention will become apparent to thoseskilled in the art after a reading of the following detailed descriptionof the invention, including the figures and appended claims.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A shows a top view of an exemplary embodiment of a portion of afootbed having a plurality of burstable packets containing differentcomponents of a curable material that when mixed react to form a solidor semi-solid resin or a gel.

FIG. 1B shows a prospective view of the exemplary embodiment of aportion of a footbed according to FIG. 1A.

FIG. 1C shows a side view of the exemplary embodiment of a portion of afootbed according to FIG. 1A.

FIG. 2A shows a side profile of a portion of an exemplary embodiment ofa packet array sheet where the packets have been filled with reactivecomponents for forming a silicone resin prior to sealing withinelastomeric top and bottom layers.

FIG. 2B shows a top view of the exemplary embodiment of a packet arraysheet according to FIG. 2A.

FIG. 3 shows an exemplary embodiment of footbed forming plates of thepresent invention.

DETAILED DESCRIPTION

This invention relates to an improved footbed technology that provides acustom-fit, mold-on-demand footbed which molds to the contours of thefoot, is pliable, and has the feel of a gel. Please note that in thisapplication, the terms “footbed”, insole”, and “insert” are usedinterchangeably. In particular, a customizeable footbed comprising anelastomeric bottom layer and a layer of burstable packets coupled to thebottom layer, wherein at least one of the burstable packets have acurable liquid may be provided. The footbeds of the present inventioncontain a top layer and bottom layer with packets, capsules, blisterpackets, blisters or bladders (hereinafter referred to as “packets”)arranged in between the two layers, e.g., the top layer and the bottomlayer. In one embodiment, the top layer and the bottom layer may definean intermediate space therebetween. A plurality of packets may bearranged in the intermediate space and may each have an exteriormembrane defining a chamber therein. The chambers may be filled with aninterior filling, which may comprise a component of a two-component ormulti-component curable material. The components of the curable materialmay chemically react, e.g., crosslink, to form a solid or semi-solidresin or a gel. The exterior membrane of the packets may be formed froma material such that the packets burst during a custom-fit moldingprocess, thereby releasing components of the curable material andallowing the components to be mixed with each other. Packets may takedifferent shapes, sizes, two-dimensional positioning, or wall thicknessin order to tune the packet's burst strength. In some applications, itmay be important that certain packets burst before others so a mixtureof burst strengths may be desired.

More particularly, the packets may contain components that set or cureupon release from the bursted packets and may combine and react withcontents of adjacent packets to initiate curing. Upon mixture of thecomponents, the curable material may begin to cure or set, with orwithout further reaction or stimuli. In some embodiments, the componentsof the curable material may spontaneously react with each other uponmixing of the components. In other embodiments, a portion of the packetsmay contain a catalyst and/or a crosslinking reagent for inititiating achemical reaction, in particular, a cross-linking reaction betweendifferent components of the curable material.

When in use, the footbed with the mixed components may be held against auser's foot such that the curable material cures or sets in a shape thatconforms to the contours of the user's foot. The different componentsreleased from the packets may flow into each other and pool within theintermediate space, particularly in areas under the foot where voidesmay exist, e.g., under the arch area, or around the toes. The mixedcomponents may begin to set and cure and solidify after a period oftime, preferably a short period of time, such that the curable materialsurrounds and corresponds to a contour of the foot, e.g., defining aperimeter of the foot and flowing betwewn the toes, arch and metatarsalareas. For example, the curable material may flow under the midfoot oran arch area of the foot, which allows the material to cure and set toprovide a cured and lasting impression of the contours of midfoot, archor the entire foot.

In one exemplary embodiment, the top and bottom layers are both made ofan elastomeric film, and the packets arranged in between the two layersare made from a thermoplastic material. These packets can containmaterials that begin to set or cure upon release from the packets andmixing/reacting with contents of adjacent packets. The packets arearranged in arrays and compartments and can be configured to optimizefit upon cure. The packets are arranged in arrays, separated intosections or compartments that correspond to different parts of the foot,e.g., section for toes, section for arch, section for heel (See FIGS.1A, 1B and 1C). During the custom-fit molding process, the user placesthe footbed within the shoe, and places his or her foot within the shoeon top of the footbed. The user then presses down on the footbed androcks the foot back and forth, causing the packets to burst and thepackets' contents to mix and react. The mixed material cures to thecontours of the foot.

As discussed above, the footbed may comprise a top layer. The top layermay be configured such that in an operating configuration, i.e., whenthe footbed is being worn by a user in footwear (e.g., inserted into ashoe), the top layer faces a bottom of a foot of the user. The top layermay comprise any suitable material that is wearable against a body part,in particular, that is comfortable against the bottom of the foot, forexample, a fabric and/or a polymeric film. In one embodiment, the toplayer may comprise a fabric. In another embodiment, the top layer maycomprise an elastomeric material, in particular in the form of anelastomeric film. In an alternative embodiment, the top layer maycomprise a thermoplastic material, e.g., a thermoplastic polymer. Moreparticularly, the thermoplastic material may comprise a thermoplasticpolyurethane (TPU), e.g., a TPU laminate with fabric. The top layer mayhave any suitable thickness. In some exemplary embodiments, the toplayer may have a thickness from about 0.5 mm to about 10 mm, from about0.5 mm to about 5 mm, or from about 1 mm to about 3 mm.

The footbed may also comprise a bottom layer, which may be configuredsuch that in an operating configuration, i.e., when the footbed is beingworn by a user in footwear (e.g., inserted into a shoe), the bottomlayer is opposite the top layer away from the bottom of the foot of theuser. The bottom layer may also comprise any suitable material, forexample, a polymeric form former, that is comfortable for insertion intofootwear (e.g., a shoe). In one embodiment, the bottom layer maycomprise an elastomeric material, in particular in the form of anelastomer film. In an alternative embodiment, the bottom layer maycomprise a thermoplastic material, e.g., a thermoplastic polymer. Moreparticularly, the thermoplastic material may comprise a thermoplasticpolyurethane (TPU) film. The bottom layer may have any suitablethickness. In some exemplary embodiments, the bottom layer may have athickness from about 1 mm to about 15 mm, from about 3 mm to about 12mm, from about 5 mm to about 10 mm, or from about 7 mm to about 9 mm.

In one exemplary embodiment, the top layer and/or the bottom layer ispreferably made from a breathable, anti-bacterial, anti-fungal and/oranti-odor material. In another exemplary embodiment, the top layerand/or bottom layer may comprise anti-bacterial, anti-fungal and/oranti-order agent embedded within a polymeric film (e.g., an elastomericfilm or a thermoplastic film).

FIGS. 1A, 1B and 1C show an exemplary embodiment of a portion of afootbed 100 having a plurality of burstable packets 1 containingdifferent components of a curable material that when mixed react to forma solid or semi-solid resin or a gel. Each of the packets 1 may comprisean exterior membrane defining a chamber therein for holding an interiorfilling. The exterior membrane may be formed of any suitable materialthat are configured to burst upon application of pressure from the userof the footbed, typically by natural motion of hand(s), foot or feet ofa user. In particular, the plurality of packets may be configured suchthat it bursts upon the foot being rocked back and forth on the footbed.By bursting, it is meant that the packets are releasing its interiorfilling by any suitable means, for example, by rupturing the filmstructure of the exterior member, or delaminating one or more, seals,adhesives, seams of the exterior membrane that define the chambertherein. Alternatively, the plurality of packets may be configured toburst upon manual application of pressure from the user's hands, such asa pressing or a twisting motion by the hands. The plurality of packetsmay also be bursted upon bending, crushing, wringing, rolling, foldingof the footbed by the hand(s), foot, or feet of the user. The packetsmay preferably be burstable by hand or foot. In some embodiments, thepackets may be burstable with (i.e., have a burst strength of) apressure ranging from 0.1 N/cm² to 1 kN/cm²; more preferably the packetsmay be burstable with (i.e., have a burst strength of) a pressure withburst strength of between 5 and 100 N/cm², and even more preferably thepackets may be burstable with (i.e., have a burst strength of) less than50 N/cm². These metrics can easily be converted to psi. In someembodiments, the plurality of packets within the intermediate space mayhave different burst strengths. For example, a first component ofcertain curable materials may need to be released before mixing with asecond component of that curable material. Therefore, those packets thatcontain the first component may have a lower burst strength than thosepackets that contain the second component, and thereby releasing thefirst componet into the intermediate space before release of the secondcomponent to mix with the first component.

In some embodiments, the interior chamber of the packets may be filledwith liquids having high viscosities such that additional mixing by anexternal source may be necessary. Typically, such additional source formixing may be applied by hand or by foot or feet of a user with any typeof motion, typically natural motion. For example, such high viscosityfluids may have a viscosity of greater than 1000 cps, greater than 1200cps, or greater than 1500 cps. The user may burst some or all of thepackets by hand prior to putting the insert into the shoe, to aid inmixing, reduce mixing time, or otherwise aid in the custom-molding. Forexample, the user may apply pressure from the user's hands, such as apressing or a twisting motion by the hands. The user may also applyadditional pressure and mixing by foot, such as by rocking back andforth while standing or pressing against the footbed.

The exterior membrane of the packets may be formed from any suitablematerial that can discharge the interior filling therein uponapplication of the desired pressure, as discussed above. In oneparticulr embodiment, the exterior membrane comprises a thermplasticpolymer, e.g., a thermoplastic film former. More particularly, thethermoplastic material may comprise a thermoplastic polyurethane (TPU)or a low density polyethylene (LDPE), which may be in the form of apolymeric film. The exterior membrane may have any suitable thickness.In some exemplary embodiments, the exterior membrane may have athickness or an average thickness from about 1 mm to about 20 mm, fromabout 3 mm to about 18 mm, or from about 5 mm to about 15 mm, or fromabout 8 mm to about 12 mm. In one particular embodiment, the exteriormembrane may have an average thickeness from about 5 mm to about 10 mm.The exterior membrane may also be formed from two or more separatesheets of polymer film that are sealed together by any suitable means,including a seal, a weld, an adhesive, etc., which are discussed furtherbelow.

As discussed above, the burstable packets 1 may contain differentcomponents of a curable material that when mixed react to form a solidor semi-solid resin or a gel. Generally, the packets may contain solid,liquid or gaseous components (or mixtures thereof or suspensionscontaining such) that, when mixed, result in some chemical reaction thatcures the materials to become a solid in the desired shape and form. Insome embodiments, the mixing or reaction may also produce some othereffect or attribute such as heat, cold, light, or color change. Thecolor change may aid in identifying whether the bursting and mixing hasbeen performed sufficiently. Each packet may contain one or more of thesolid, liquid or gaseous component. In particular, the packets can befilled with a range of two-component or multi-component reactiveliquids. For example, each packet may contain one or more of thereactive liquids. Examples of reactive liquids are two-component resins,such as polyurethane resins, silicone resins, epoxy resins, melaminresins, and polyurea resins; multi-component liquid reactants to affectthe production of heat, such as in the dissolution of calcium chlorideinto water; multi-component liquid reactants to affect the lowering ofthe temperature, such as the dissolution of ammonium chloride intowater; and multi-component liquid reactants to affect the production oflight, such as the mixing of luminol and hydrogen peroxide.

In some exemplary embodiments, the components of the curable materialmay chemically react, e.g., crosslink, to form a solid or semi-solidresin or a gel. Suitable curable materials may include polyurethaneresins, silicone resins, epoxy resins, melamin resins, and polyurearesins. The components may further comprise additional additives thatmay impart a detectable change upon reaction, e.g., a color change oractivating chemiluminescence (e.g., mixing of luminal and hydrogenperioxide). The reaction of the components of the curable material maybe either exothermic (i.e., generate heat) or endothermic (i.e., reducesheat). However, the exothermic or endothermic changes of the reactionshould be within a tolerable range of temperature changes to the humanskin, for example, the exothermic reaction should not release energythat raises the temperature of the footbed to above 90° C., prefereablythe temperature should be maintained below 75° C., more preferably below50° C. Similarly, the endothermic changes of the reaction should notreduce the temperature of the footbed to below 0° C., preferably thetemperature should be maintained above 10° C., more preferably above 20°C.

In particular, the components of the curable material may comprise afirst component comprising monomers, and a second component comprisingcrosslinking reagents. Alternatively, the components of the curablematerials, e.g., monomers for crosslinking, may be reactive uponexposure to air or components found within ambient air, such as moistureor oxygen. In other embodiments, a portion of the packets may contain acatalyst and/or a crosslinking reagent for initiating a chemicalreaction, in particular, a cross-linking reaction between differentcomponents of the curable material. In some embodiments, the componentsof the curable material may spontaneously react with each other uponmixing of the components.

Suitable two-component curable materials may include a first component(which is also referred to herein after as Component A), and a secondcomponent (which is also referred to hereinafter as Component B). In oneparticular embodiment, the two-component curable material may be asilicone. For example, Component A and Component B may comprise avinyl-terminated dimethylpolysiloxane and a silicon-hydride crosslinkerwith platinum catalyst, respectively. In particular, the two-componentsmay comprise commerically available silicone components: Andisil®204-37C and Andisil® 204-37D.

In a preferred embodiment, the components of the curable material maycomprise different reagents for a quick-cure or quick-set curablematerial. For example, the components of the quick-cure or quick-setcurable material may begin to cross-link upon mixing of the componentswith each other. The quick-cure or quick-set curable material may form asolid or semi-solid resin or a gel in the desired shape, e.g.,conforming to contours of a foot, as it crosslinks within about 1 hourof initial mixing, preferably within about 45 mins of initial mixing,more preferably within about 30 mins of initial mixing, and even morepreferably within about 20 mins of initial mixining. Even morepreferably, the quick-cure or quick-set curable material may solidify orgel within a short period of time, e.g., less than 5 mins, or less than3 mins.

The plurality of packets may have any suitable shape. In someembodiments, the packets may be made in different three-dimensionalstructures, aspect ratios, and overall dimensions, including but notlimited to height, width, and wall thickness for different applications.The three-dimensional structure of the packets can be anythree-dimensional closed solid compromising flat, contoured and/orcurved surfaces; some examples are hemi-spherical, cubic, hexagonalprism, pentagonal prism, square prism, rectangular prism, cone, andtetragonal pyramid shapes. In some embodiments, the plurality of packetsmay all have a uniform size and/or shape. For example, as shown in FIGS.1A, 1B, and 1C, the packets may each have a square prism shape. In oneexemplary embodiment, the packets may have a square prism shape havingan aspect ratio (i.e., a ratio of a side of a square to the height ofthe prism) from about 1:2 to about 2:1. In a preferred embodiment, theaspect ratio of the square prism may be about 1:1. In certain exemplaryembodiments, the width of a side of the square prism may range fromabout 0.1″ to about 0.5″, preferably from about 0.125″ to about 0.5″.

Alternatively, the packets may each have a regular or irregularthree-dimensional shape and may have any suitable aspect ratio. For anirregular shape, the aspect ratio may be defined as a ratio of anaverage lateral cross sectional diameter to a height of the shape, whichmay range from about 1:2 to about 2:1, and preferably about 1:1. Theabove describe aspect ratios are not limited to irregular shapes, butmay be also used for any suitable polygonal three-dimensional shape.

Furthermore, the plurality of packets may be arranged two-dimensionallyon a flat or curved surface. For example, the plurality of packets maybe arrange across the bottom layer of the footbed. The curvature of thetwo-dimensional array may be optimized to maximize the ease of packetbursting by the user. The spacing, distribution, shape, and size of thepackets can also be varied to maximize the ease of bursting by the user.The spacing between the packets may vary between a nil thickness and 100centimeters. More particularly, the spacing between packets may rangefrom about 0.01″ to about 0.5″, from about 0.03″ to about 0.3″, or fromabout 0.05″ to about 0.1″. Packets may be all the same size and shape orcomprise a variety of different shapes within the same footbed. In oneembodiment, the packets may be arranged to form a two-dimensionalarrange along the length and width of the footbed. Such an arrangementmay be useful for optimizing fit against an entire contour of the footupon mixing and curing of the components of the curable material.

The most preferable arrangement of packets is a pattern of identicalshaped and sized close-packed polygonal prisms, such as cubes,rectangular prisms, or hexagonal prisms. This arrangement allows the airto be evacuated efficiently from the outside thermoplastic, elastomericbag. In this arrangement, a two-component resin can be distributed inpackets such that parts A and B (i.e., the parts to be mixed) are spacedout in separate packets an alternating fashion. Such an alternatingarrangment may further allow for through mixing of components A and Bupon bursting of the packets.

As shown in FIGS. 1A, 1B, and 1C, the plurality of packets may bearranged into a two-dimensional array. For example, the plurality ofpackets may have a square prism shape and arranged into an array thatresembles a grid. Each packet, which has a square prism shape, may bespaced a predetermined distance from an adjacent packet. Moreparticularly, the spacing between packets may range from about 0.01″ toabout 0.5″, from about 0.03″ to about 0.3″, or from about 0.05″ to about0.1″. In some embodiments, the packets may contain two differentinterior fillers: a first interior filler containing a first componentof a two component curable material (which is also referred to hereinafter as Component A), and a second interior filler containing a secondcomponent of a two component curable material (which is also referred tohereinafter as Component B). Each of the plurality of packets in thegrid may be filled in an alternating such that no packet contains thesame type of filler as an adjacent packet, as shown for example below:

A B A B A B B A B A B A A B A B A B B A B A B A A B A B A B

In some embodiments, the plurality of packets may be arranged to formmultiple arrays arranged across different sections of the foot. In oneembodiment, the plurality of packets may be arranged to form at least afirst two-dimensional array across a first section of the footbedcorresponding to a first portion of the foot, and second array forming asecond section of the footbed corresponding to a second portion of thefoot. In one exemplary embodiment, each section is sealed from the nextsection such that no fluid communicates between the different sections.In some embodiments, each section may be compartmentalized to controlthe flow of the components of the curable material to different areas ofthe foot. For example, an area of the footbed corresponding to the toesmay comprise one compartment/section of burstable packets, an area ofthe footbed corresponding to an arch area of the foot may compriseanother compartment/section of burstable packets, and an area of thefootbed corresponding to a heel portion of the foot may also comprise afuther compartment/section of burstable packets to direct curablematerial to desired locations to allow for improved shaping of thefootbed to provide proper foot support in these desired regions.

Each section may also include packets that are sized and shaped suitablefor that particular section, for example, a first section may comprisean array having a first set of uniformly sized and shaped packets thatare different from a second set of uniformly sized and shaped packetsthat are part of a second section. Although two different sections arediscussed above, it is understood that more than two sections andtherefore, more than two two-dimensional arrays may be utilized in thefootbed of the present invention.

As can be seen in FIGS. 1A, 1B and 1C, the footbed may be separated intocompartments or regions such as a toe region 2, an arch region 3, and aheel region 4. In addition, these figures show a border surrounding thefootbed area which allows the footbed to be clamped during manufacturingprocesses.

In one exemplary embodiment, the plurality of packets may be formed bybonding together two plastic sheets, preferably two polymeric films,more particularly two thermoplastic films. The two plastic sheets thatbond together to form the packet may both be thermoformed, blow molded,or otherwise shaped to define the packet volume or only one sheet can beshaped. The preferred embodiment for the moldable footbeds is a singlyshaped low-density polyethylene sheet bonded to a flat low-densitypolyethylene sheet. In the preferred embodiment for the moldablefootbed, the polyethylene is thermally welded to the adjacent sheet todefine the seams of each packet.

Packets may be formed from any materials that can be sealed to eachother by some means. Methods of sealing the packet seams includethermally welding, sonically welding, mechanically folded together,using a curable adhesive, or using a hot-melt adhesive orthermoplastic). For other applications, the packets could be formed bythermal or sonic welding of thermoplastic sheets or it may be desirableto use an adhesive or other material to form a significantly stronger orweaker bond to tune the delamination of the packet seam. For example,all inner seams of the individual packets in the array may be tuned todelaminate while the outer seams remain laminated such that the packetarray becomes one continuous pouch after bursting. The shaped plasticsheet could also form packets with hard non-porous surfaces, such asglass, metal, rock, or a coated surface.

In a preferred method of making the footbed of the present invention,the packet arrays are formed by vacuum forming thermoplastic sheets intobubble sheets. The thermoplastic material can survive strenuousconditions during manufacturing, shipment and handling but bursts whenbody weight pressure is applied. This prevents premature curing andpreserves on-demand molding functionality. The arrayed packets arefilled with resin and a backing layer is thermally sealed to the openback of the packets to form an arrayed sheet of packets, which can beseen in FIG. 2. The arrayed packet spacing and individual packet volumecan be optimized in order to achieve the desired resin volume. Whenmultiple components are desired, packet characteristics can becustomized in order to contain the required volume. Also, an arrayedpacket design allows for quick mixing by holding components in closeproximity to each other. Upon bursting, each packet of material can bein close proximity to other packets. The preferred embodiment has anarray of packets optimized for the desired volume and with curingcomponents in close proximity.

In another embodiment, the footbed of the present invention may beenclosed in a compartment within the shoe. The footbed may be enclosedin a way that it may be slid in and out, removed and replaced, orpermanently enclosed.

The footbed may be included in an item of self-customizing footwear. Theitem of self-customizing footware may comprising an upper, an insole,and an outsole, wherein the insole comprises an elastomeric upper layerpositioned to contact with the bottom of the foot; an elastomeric bottomlayer coupled to the outsole; and a middle layer enclosed between theupper layer and lower layer; and the middle layer comprising a pluralityof burstable packets having a curable liquid material. Additionally. atleast some of the burstable packets are configured to burst underpressure from a foot subject to a weight bearing action, and whereinupon bursting, the curable liquid material flows within the enclosedmiddle layer to conform to and solidify in the shape of the foot. Themiddle layer may also be divided into a plurality of compartments,wherein the quantity and/or composition of curable liquid materialdiffers between each of the compartments. Furthermore, the compartmentsmay be configured to control flow of material and compensate fordifferent pressure applied by different portions of the foot during theweight bearing action.

EXAMPLES Example 1

The steps for producing footbeds of a preferred embodiment of thepresent invention are as follows: First, materials are prepared bycutting LDPE, TPU, fabric, and transfer adhesive to the proper sizerequired. With the LDPE sheeting, custom bubble arrays are formed byvacuum thermoforming of the film. The LDPE sheeting is brought intoclose proximity of a high temperature heat source, kept at 275° C. Oncethe material begins to soften and exhibits characteristics of melting,the sheeting is then brought into contact with a custom mold that isarranged on a vacuum plate, allowing the softened material to form a netshape of the custom mold. Once this custom bubble arrangement is formed,the piece is then placed into a custom holder with rigid channelsbetween the formed bubbles, allowing the bubbles to hang freely. In thisholder, silicone components are then loaded into the bubbles in analternating fashion. Once the bubbles are filled, a sheet of LDPE isthen laid across the loaded bubbles. Using a high temperature and highpressure pneumatic thermal press, this film is pressed into the custombubble arrays, forcing a high pressure gradient where the rigid channelbelow lies, allowing the LDPE to seal to itself through the siliconecontamination. This completes the formation of the silicone loadedbubble arrays.

Using the prepared TPU sheeting, two films are placed directly on top ofone another and a desired fabric top cover is applied to the top surfaceusing a double sided transfer tape adhesive. With the fabric in place,the silicone loaded bubble array is aligned in proper position inbetween the two TPU sheets. With this array in place, three sides of thefilm stack are heat sealed, creating TPU-TPU bonds around the outeredge. With these seals completed, the final open side is then used toevacuate the excess air held within the films, creating a vacuum tightseal of the TPU sheeting around the custom bubble arrays. Once the airhas been evacuated, the TPU sheets are then heat sealed using a customsealing plate kept at high temperature and pressure, forming the overallshape of an insole complete with sealed partitions in specific areas ofthe insole to separate bubbles in certain regions of the foot. Once thisseal has been created, the net shape desired for further manufacturingis then cut and the custom moldable layer of the insole is completed.

The materials used for the production of the insoles, including thecommercial suppliers' information, are as follows:

-   -   a. Silicone filler material is Andisil 204-37 Parts C&D,        supplied by AB Specialty Silicones    -   b. Bubble films formed from LDPE, 10 mil film thickness,        supplied by SC Johnson. Film with no slip additive preferred.    -   c. TPU sheeting is product DT-7101, 8 mil film thickness,        supplied by American Polyfilms Inc.    -   d. Fabrics provided by Cosmo Fabrics

Example II

In another embodiment, the packets may be formed in a square prismblisters having the following aspect dimensions. 0.25″×0.25″×0.25″ (1:1aspect ratio). The packets may contain two different interior fillers (Aand B) arranged in an alternating fashion. Each packet may be spacedapart from an adjacent packet by a gap between 0.05″-0.1″.

The materials used for the production of the insoles, including thecommercial suppliers' information, are as follows:

Interior filling/silicone:

Andisil® 204-37C having a viscosity—1950 cps

Andisil® 204-37D having a viscosity—1450 cps

1:1 mixed gel time (20 sec mix)—55 sec

Properties—cure 20 minutes at RT:

Bottom TPU Layer: Product: DT 7101, polyether TPU film

Top Fabric Specs:

Product: Jump Spacer+2 mil TPU Laminate+Print

Company: Cosmo Fabrics

Packet exterior membrane: LDPE

The invention described and claimed herein is not to be limited in scopeby the specific embodiments herein disclosed since these embodiments areintended as illustrations of several aspects of this invention. Anyequivalent embodiments are intended to be within the scope of thisinvention. Indeed, various modifications of the invention in addition tothose shown and described herein will become apparent to those skilledin the art from the foregoing description. Such modifications are alsointended to fall within the scope of the appended claims. Allpublications cited herein are incorporated by reference in theirentirety.

What is claimed is:
 1. A customizeable footbed comprising: a top layerwhich, when the footbed is in an operating configuration faces a bottomof a foot; a bottom layer opposite the top layer which, when the footbedis the operating configuration is positioned away from the bottom of thefoot, the top and bottom layers defining an intermediate spacetherebetween; and a plurality of packets arranged within theintermediate space, each packet comprising an exterior membrane defininga chamber therein, and an interior filling within the chamber, theinterior filling being selected from a group consisting of two or morecomponents of a curable material that chemically react upon mixing ofthe components to irreversibly form a solid or semi-solid resin or agel, wherein the plurality of packets are configured to burst uponapplication of a pressure corresponding to that of the foot being rockedback and forth on the top layer such that the interior fillings of thepackets flow into and mix within the intermediate space.
 2. Thecustomizable footbed of claim 1, wherein the bottom layer comprises anelastomeric polymer.
 3. The customizable footbed of claim 1, wherein theexterior membrane comprises a thermoplastic polymer.
 4. The customizablefootbed of claim 3, wherein the exterior membrane comprises alow-density polyethlyene polymer.
 5. The customizable footbed of claim3, wherein the exterior membrane has an average thickness from about 5mm to about 10 mm.
 6. The customizable footbed of claim 1, wherein thecurable material is a two-component or multi-component resin thatspontaneously reacts upon mixing of the components.
 7. The customizablefootbed of claim 6, wherein the curable material is selected from agroup consisting of polyurethane resins, silicone resins, epoxy resins,and melamin resins.
 8. The customizable footbed of claim 1, wherein thecurable material is a quick-curing material that solidifies into adesired shape within 30 mins upon mixing of the components.
 9. Thecustomizable footbed of claim 1, wherein the plurality of packets areconfigured to burst upon application of a pressure from about 0.1 N/cm²to 1 kN/cm².
 10. The customizable footbed of claim 1, wherein each ofthe plurality of packets has a three-dimensional shape.
 11. Thecustomizable footbed of claim 1, wherein the three-dimensional shape isselected from a group consisting of hemis-spherical, cubic, hexagonalprism, pentagonal prism, rectangular prism, square prism, cone, andtetragonal pyramid shapes.
 12. The customizable footbed of claim 11,wherein each of the plurality of packets has a square prism shape 13.The customizable footbed of claim 12, wherein a ratio of a width and aheight of the square prism is from about 1:2 to about 2:1.
 14. Thecustomizable footbed of claim 13, wherein a ratio of a width and aheight of the the square prism is 1:1.
 15. The customizable footbed ofclaim 1, wherein the plurality of packets are uniformly sized andshaped, and arranged in a two-dimensional array.
 16. The customizablefootbed of claim 15, wherein the packets are spaced apart by a distancefrom about 0.05″ to about 0.1″.
 17. The customizable footbed of claim 1,wherein the plurality of packets are arranged to form at least a firsttwo-dimensional array across a first section of the footbedcorresponding to a first portion of the foot, and a second array forminga second section of the footbed corresponding to a second portion of thefoot.
 18. The customizable footbed of claim 1, wherein the plurality ofpackets are formed from a singly shaped polymeric film bonded to a flatpolymeric film.
 19. A self-customizing footwear comprising: an upper, aninsole, and an outsole, wherein the insole comprises a top layer which,when the insole is in an operating configuration is faces a bottom of afoot; a bottom layer opposite the top layer which, when the insole isthe operating configuration is positioned away from the bottom of thefoot, the top and bottom layers defining an intermediate spacetherebetween; and a plurality of packets arranged within theintermediate space, each packet comprising an exterior membrane defininga chamber therein, and an interior filling within the chamber, theinterior filling being selected from a group consisting of two or morecomponents of a curable material that chemically react upon mixing ofthe components to irreversibly form a solid or semi-solid resin or agel, wherein the plurality of packets are configured to burst uponapplication of a pressure corresponding to that of the foot being rockedback and forth while wearing the footware such that the interiorfillings of the packets flow into and mix within the intermediate space.20. A method for customizing a footbed to conform to contours of a foot,comprising: applying a pressure to burst a plurality of packets, eachpacket comprising an exterior membrane defining a chamber therein, andan interior filling within the chamber, the interior filling beingselected from a group consisting of two or more components of a curablematerial; mixing the components of the curable material to initiate achemical reaction such that the components irreversibly react to form asolid or semi-solid resin or a gel; and holding the foot against thefootbed for a period of less than 30 mins such that the curable materialreacts to form a shape comforming to the courtours of the foot.
 21. Acustomizeable footbed comprising: a top layer; a bottom layer; and aplurality of blister packets arranged between the top and bottom layers,each packet comprising an exterior membrane defining a chamber therein,and an interior filling within the chamber, the interior filling beingselected from a group consisting of two or more components of a curablematerial that chemically react upon mixing of the components toirreversibly form a solid or semi-solid resin or a gel, wherein theplurality of blister packets are configured to rupture upon applicationof a pressure corresponding to that of the foot being rocked back andforth on the top layer such that the interior fillings of the packetsintermix.